Nonwoven textile structures with reversible stretch

Abstract

A nonwoven textile structure which exhibits improved stretch/recovery characteristics comprises a blend of staple fibers having a first component of crimped nonelastic fibers and a second component of quasi-elastic fibers, the crimped and quasi-elastic fibers being bonded together at predetermined intervals less than the staple fiber length and greater than the crimp length.

What I claim is: 
     
       1. A nonwoven textile structure which exhibits improved stretch/recovery characteristics, said structure comprising a blend of staple fibers having a predetermined minimum staple fiber length and including a first component of nonelastic crimped fibers having a predetermined crimp length and a second component of quasi-elastic fibers, said crimped and quasi-elastic fibers being bonded together at intervals less than said minimum staple fiber length but greater than said crimp length, said quasi-elastic fibers being substantially uncrimped. 
     
     
       2. A nonwoven textile structure as in claim 1 wherein said crimped fibers are selected from the group consisting of nylon, polypropylene and polyethylene terephthalate staple fibers. 
     
     
       3. A nonwoven textile structure as in claim 2 wherein said quasi-elastic fibers are selected from the group consisting of SEF modacrylic and polymethylene terephthalate staple fibers. 
     
     
       4. A nonwoven textile structure as in claim 1 wherein the crimp length is less than about 0.10 inches. 
     
     
       5. A nonwoven textile structure as in claim 1 wherein the crimp length is between about 0.05 inches and about 0.10 inches. 
     
     
       6. A nonwoven textile structure as in claim 1 wherein said second component comprises at least 30% of said blend. 
     
     
       7. A nonwoven textile structure as in claim 1 wherein said staple fiber length is at least 1 inch. 
     
     
       8. A nonwoven structure as in claim 1 wherein said staple fiber length is between about 1 inch and about 17/8 inches. 
     
     
       9. A nonwoven textile structure as in claim 1 wherein said staple fiber length is about 11/2 inches. 
     
     
       10. A method of producing a nonwoven textile structure having improved stretch recovery characteristics, said method comprising the steps of: (a) blending a first component of staple nonelastic crimped fibers having a predetermined crimp length and a second component of staple substantially straight quasi-elastic fibers to form a nonwoven batt, the first and second components having a minimum predetermined staple fiber length; and   (b) bonding the fibers of the first and second components comprising the batt formed according to step (a) at predetermined intervals less than said minimum staple fiber length and greater than said crimp length.   
     
     
       11. A method as in claim 10 wherein step (b) is practiced utilizing ultrasonic bonding means. 
     
     
       12. A method as in claim 10 wherein said first component fibers are at least one selected from the group consisting of nylon, polypropylene and polyethylene terephthalate staple fibers. 
     
     
       13. A method as in claim 12 wherein said second component fibers are at least one selected from the group consisting of SEF modacrylic and polymethylene terephthalate staple fibers. 
     
     
       14. A method as in claim 10 wherein said second component comprises at least 30% of said batt.